Knuckle build update..

My new front wheel - an aluminum 21" DID from an '82 Yamaha TT250 with a nice useable trials type tire on it found it's way to chez Whiz yesterday while we were having a party to celebrate my wife Susie's 50th birthday.. I propped it up in the position it'll be with a springer front end.

Knucklehead build update..

Here's a taster.. Awaiting delivery of the front end and some other parts next week.. The motor is having some machining done to the bottom end and parts will be ordered for the rebuild as soon as some extra dough has flowed too! I'm going to tack the gas tank together next and get a fender that'll flow and suit that p-pad and a small sissy bar..

Knuckle build...

Ditto..

Knuckle build..

Some clearcoat info I needed for when I paint the tank..

Knucklehead build..

I'm going to be cleaning up the inside of the tank halves thoroughly as they're a bit oily - ish. Then I'm going to tack it up with my flux wire welder ready for TIG'ing. I have ordered a gas cap & bung - and a lil' bung for a petcock too.. If the tank comes out as I hope I will use it on this build & keep the other tank I bought for the next bike.

Knuckle build..

Just a lil' taster of the style - that's an ol' seat I bought offa Ebay too - was 'sposed to be a Bates.. hell I'll probably get a genuine one of those one day..

Knuck build..

Rear view.. Btw my tasty patina'd brake plate I got off of the 'bay from Kentucky sits waiting patiently for the 18" sportster wheel to arrive from New York..

Knuck build..

This was what I removed..

Knuck build..

I was a bit surprised just how good the tank looked after the butchery..

Knuck build..

Aw, hell.. while I was out there in the yard with the tools handy I chopped the center out of that new sporty tank cuz I really dig that narrow slinky look when the tunnel area is removed - I wanted to mount the tank frisco style anyways..

Knuck build..

..I wanted to clear some room to mount my Sportster gas tank..

Knuckle build progress..

I shaved off some metal in the frame neck area today - tried to keep it looking nice as I love the old Harley castings BUT..

Knucklehead build..

I have got done on Ebay for now - I have junk winging it's way from all over the country which hopefully we can make work for this build! I'm also going to pop over to Mike O's tomorrow all being well - we're gonna get a parts list together for the bottom end of the '47 motor & put in an order for what we need - get the ball rolling.. I'm going to need a few more dead presidents for the transmission and a carb etc - but the plan is to roughly assemble the bike and get the ol' motor rebuilt then tackle the final details as funds permit.

Knucklehead build progress..

OK Sorry no pictures yet but I have been busy scouring Ebay.com for parts to get this build on track.. I'm going down the patina route this time - wish I had last time as things ended up a little too "new" and soul-less for my tastes these days on my shovelhead build a couple years back. I've found a nice 18" early sportster rear wheel - with tire too; a nice patina'd steel brake plate/innards - just need a rear drum now & that's the back end sorted.. I needed to get cheaper at the front having paid about $200 for the rear wheel/tire complete so I went Japanese (as last time) & found a 21" Yamaha or Honda aluminum DID rim laced with decent sized spokes to a small drum brake & a trials type tire fitted too.. $70 inc. shipping from AZ. Cool..
I have found a great looking gas tank - basically a narrowed sporty design - but it's new & built that way - that limits me to a raw or painted finish - no patina on this piece; seat-wise I have my eye on another original '70s solo seat in vinyl - that may get too pricy on EB for me though. I am also bidding on a plain steel oil bag - again new but a nice shape cylindrical tank. It gets fun Ebaying when you get in the swing of it again!

Knucklehead build..

I turned my attention to the frame - don't know any history with this frame but I can see that probably it was raked out in the seventies sometime - then returned somewhat to stock with a neck casting welded back in - probably without using a jig. The frame is a little out of alignment but I know I can straighten it up - I grabbed some paint stripper and got to work to get it back to metal - this gave me that first thrill of seeing how my new ride is gonna look - I'm going to go with a nice raw frame - lots of patina there already.. Luvverly!

Knucklehead build..

Mike has seen a lot of older Harley motors over the years & rebuilt a whole bunch of them - he told me that the thrust in the rods at the big end had been lost - possibly due to an over-tight set-up - resulting in excess heat and abnormal wear. There may have been an oiling issue too - who knows? One of the main bearing outer races in the case had even loosened. The inside of the cases looked good though - no nasty surprises there. There was also wear in the cylinder bores - at +.030" now - we agreed that a .010" cut would sort that and new +.050" jugs & rings will be used. I need a new crank-pin - probably gonna use a three hole oiling version. Mike is going to take care of all the fiddly engineering jobs as he has the tools, jigs and the experience too! I want to watch and continue to pick up as much knowledge as possible though..
We are going to toss the camshaft too.

Knucklehead build..

We headed over to my friend Mike's 'shop nearby to show him the knuckle motor for his appraisal: I whipped the cases apart & Mike split the flywheel assembly whilst I watched to learn how it was done. A small fixture to hold the crank whilst the crankpin nuts were loosened & the tapers broken came in handy and all was soon revealed..

Knucklehead build..

Sharing space with my ever patient wife Suzie..

Knucklehead build..

I just feel so lucky to get hold of a knuckle motor to be honest..

Knucklehead build..

Before anything else I had a play around to see how the timing side of the motor worked and find out if anything obvious was missing or worn.. I could feel wear in the cam journals & or bushings although the cam lobes were OK. The oil pump worm gear on the crankshaft pinion shaft was missing as was the breather gear.. Most everything else was present though which is cool.

Knucklehead build..

Gonna go see the frame today - check that out, also pop over to Mike Olsen's and show him the motor see if we can work out a plan to get her makin' noise again soon..

Knucklehead build..

It's nice working indoors..

Knucklehead build..

I whipped the top end off the Knuck today ready for my buddy Mike Olsen to inspect..

Knucklehead build..

Feels a bit like Xmas.. But I'm gonna keep my feet firmly planted and hope that the motor is as good as it looks from first impressions. I'm hoping that we'll be looking at an inspection and wet build rather than a total rebuild now. Fingers crossed! Going to take the motor over to a friend who's an experienced vintage Harley man for a look see before anything else..

Mmm..

I'll take the motor - less trouble from the missus'..

Wow...

I been waiting all weekend - oh, and a few years I 'spose too for this day.. It's a bit like staring at Emma Stone - naked and ready! Oh OK I'm just an ol' pervert sure..